US20120152439A1 - Surface repair patch - Google Patents
Surface repair patch Download PDFInfo
- Publication number
- US20120152439A1 US20120152439A1 US13/406,976 US201213406976A US2012152439A1 US 20120152439 A1 US20120152439 A1 US 20120152439A1 US 201213406976 A US201213406976 A US 201213406976A US 2012152439 A1 US2012152439 A1 US 2012152439A1
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- United States
- Prior art keywords
- patch
- hole
- repair
- drywall
- mesh sheet
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- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G23/00—Working measures on existing buildings
- E04G23/02—Repairing, e.g. filling cracks; Restoring; Altering; Enlarging
- E04G23/0203—Arrangements for filling cracks or cavities in building constructions
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G23/00—Working measures on existing buildings
- E04G23/02—Repairing, e.g. filling cracks; Restoring; Altering; Enlarging
- E04G23/0203—Arrangements for filling cracks or cavities in building constructions
- E04G23/0207—Arrangements for filling cracks or cavities in building constructions in hollow structures, e.g. cavity walls
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/20—Patched hole or depression
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
- Y10T428/24322—Composite web or sheet
- Y10T428/24331—Composite web or sheet including nonapertured component
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
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- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Electrochemistry (AREA)
- Mechanical Engineering (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Working Measures On Existing Buildindgs (AREA)
Abstract
This invention is a method and apparatus for repairing a hole in a surface with a perforated repair patch. The repair patch, which is affixed to and substantially cover over the hole, is indented inwards by applying cement compound into its perforations and pushing the repair patch into the hole as the cement compound hardens. A layer of drywall compound is then applied over the indented repair patch to smooth it with the rest of the wall. The perforated repair patch may include an additional layer of mesh sheet material to minimize cracking of the drywall compound.
Description
- This Application is a Continuation-in-Part of allowed U.S. Non-Provisional Patent Application No. 12/754,248, filed on Apr. 25, 2010, entitled “A Mechanically Tensioned Wall Patch”, by inventor Daniel R. Hansen, the contents of which are expressly incorporated herein by this reference, and to which priority is claimed.
- This invention relates to the method and apparatus for repairing a hole in a sheet, plate, board, fiberglass, wood, gypsum board, or drywall, with an adhesive repair patch. More particularly, the invention relates to a method and apparatus of indenting a repair patch into the hole to be patched.
- Since the advent of the drywall, and its prolific use in the construction of structures, methods and devices have been created to repair damaged portions of a drywall. Generally, there are two common types of reparable damage to a drywall: a small hole or crack; or a large hole. Large holes are typically repaired by cutting out the damaged section of the wall, placing a back board behind the cut-out hole and filling the cut-out hole with a comparable sized piece of drywall. The edges of the cut-out are then taped with paper drywall tape or fiberglass tape, and filled in and covered with drywall compound.
- Very small holes and cracks may often be repaired with just the use of drywall compound, by layering the drywall compound over the hole or crack and then sanding it down to smooth it with the rest of the wall.
- For holes that are too large to use just the drywall compound or too small to warrant the use of the cut-out and replace method, a mesh repair patch, or a mesh laminated and centered onto a smaller piece of metal, as disclosed in U.S. Pat. No. 4,135,017, issued to Hoffman, is frequently used. A mesh repair patch is a small piece of mesh, typically made out of round fiberglass threads, which is placed over the hole in the drywall. The mesh repair patch provides a workable surface for the drywall compound to adhere to in repairing the damage, but can leave an unsightly bulge, or fall away completely from the wall due to the weight of the drywall compound. Alternatively, metal laminate plates are rigid enough to support more weight, but leave an unsightly bulge that is difficult to float out and hide due to the increased thickness of the metal.
- There are numerous references that disclose devices and methods for repairing holes in walls, boards, sheets, plates, fiberglass, wood, gypsum board, or drywall using a mesh repair patch. For example, U.S. Pat. No. 7,380,382 (“the '382 Patent”), issued to Daniel R. Hansen, the same inventor of the present invention, the contents of which are expressly incorporated herein by this reference as though set forth in its entirety, discloses a laminate mesh repair patch that has an adhesive located on one side of the fiberglass mesh adhered and centered onto a smaller separate sheet of dry, water hardenable cement on the front. The mesh repair patch of the '382 Patent is placed over the hole, the sides of the patch adhere to the wall immediately adjacent to the hole, and the cement is wetted, allowed to set for about 5 minutes becoming partially rigid, but still movable, and then pushed inward to form an indentation. After the indentation sets relatively hard, drywall compound is applied to make a smooth repair. The partially rigid cement on the front of the mesh repair patch allowed the mesh laminate to be manually indented into the hole by pushing it inward with a hand or finger.
- Although the '382 Patent was a vast improvement over using the standard mesh repair patch, or metal laminate patches, without the dry, water hardenable cement on the front, it did not entirely overcome the problem of providing a repair patch devoid of an unsightly bulge. Specifically, the '382 Patent had a mesh repair patch thinner than the popular metal laminate patch, but thicker than a fiberglass mesh patch devoid of a metal plate. The '382 Patent requires that the user spray water over the patch once it is affixed over the hole and onto the wall, and rubbed with a hand to mix the plaster. With the addition of water, the '382 patch will sometimes slide off the wall, or in cold weather, will not stick at all and if the user forgets to indent the patch, the repair process must start all over. Also, if the plaster on the patch is not wetted and rubbed properly, a larger, unsightly bulge may be created. In addition, the water can cause the '382 patch to be messy and typically requires the user to purchase a water spray bottle. Finally, it can take 20 or 30 minutes, depending on atmospheric conditions, for the patch disclosed in the '382 Patent to set hard enough to complete the repair. This is a significant downside for professionals in need of an instant repair.
- Moreover, several references, including U.S. Pat. Nos. 4,406,107 (“the '107 Patent”), 6,317,952 (“the '952 Patent”), and 5,033,949 (“the '949 Patent”), disclose wall repair devices that provide a stable surface on which to apply a drywall compound to repair a hole in a wall. However, none of these references incorporate an easy to use mesh repair patch and each and every one of these references involves the use of a very complex device or method that is difficult to use or perform. For example, the '107 Patent, issued to Schoonbeck discloses a wall repair device that is comprised of two discs connected with a center bolt and nut. The larger of the two discs must be larger than the hole to be repaired and is adhered to the back of the wall. The smaller disc must be smaller than the hole to be repaired. The smaller disc is positioned along the bolt and is locked in place just rearward of the hole. The front and smaller disc acts as a stable platform for drywall compound to be applied. Although the device disclosed in the '107 Patent could potentially aid in the repair of a drywall hole, the device is very complex and is extremely limited. Specifically, there is no easy way to modify the discs to fit the randomly sized hole that may need to be repaired. Additionally, it is hard to imagine how the large disc fits through the hole in the first place since it must necessarily be larger than the hole.
- The '952 Patent discloses a device that includes a flexible plastic plate, which is bigger than the hole to be repaired and is pushed to the inside of the wall and then pulled back against the back side of the wall using a plastic zip key like device. The zip key is attached to a plastic rod, which is positioned on the outside of the wall and securely holds the plate in place. The problem with this device is that the plastic rod is in the way when the user fills the hole with plaster or drywall compound. Additionally, once the drywall compound hardens, the plastic zip key must be cut away as close to the hardened plaster as possible and removed from the patching assembly along with the plastic rod. Accordingly, an additional coat of drywall compound is required to complete the repair and cover the zip key.
- The '949 Patent discloses a back disc that is held in place in a hole by a bolt while drywall compound is filled in the hole. Before the compound is set, a front dam is attached to the bolt, and the back disc is forced forward, which causes the compound to press forward against the dam. The problem with this device is that it is extremely complicated to use and requires the user to hold the back in place while the drywall compound is applied.
- Furthermore, U.S. Pat. No. 5,620,768 (“the '768 Patent), issued to Hoffman, discloses a plastic repair patch, which functions as a rigid substrate to support the weight of a joint compound. The '768 repair patch is typically adhered onto a hole in the wall for repair and preferably includes a plurality of holes on which to apply a drywall compound. While the '768 repair patch may be “flexible” and “deformable” to conform onto uneven surfaces, the '768 repair patch remains too rigid to form an indent. This often leaves an unsightly bulge on the wall, which also remains to be a significant downside for professionals.
- Thus, what is needed is to provide a surface repair patch that is less complex than the prior art; much easier to use; and is cost-effective in repair.
- To minimize the limitations in the prior art, and to minimize other limitations that will become apparent upon reading and understanding the present specification, the present invention is a method and apparatus of indenting a repair patch into the hole to be patched.
- One embodiment of the present invention is a surface repair patch comprising: a patch; wherein the patch is affixed to an outer edge of a hole in a surface, such that the patch substantially covers the hole. The patch indents and remains substantially indented when a user applies a cement compound onto the patch. Preferably, the patch includes one or more perforations; wherein the one or more perforations receive the cement compound, such that a portion of the cement compound passes through the one or more perforations. Preferably, the surface repair patch further comprises of: a mesh sheet; wherein the mesh sheet should affix to and substantially cover the patch. The patch is preferably constructed out of a pliable sheet material. The mesh sheet is preferably constructed out of a fiberglass thread material. The patch should include an adhesive on at least one side of the patch. The patch may be an aluminum foil. The surface is typically a drywall. The hole may comprise a channel cut in the drywall. A drywall compound should be applied to the indented patch.
- Another embodiment of the present invention is a surface repair patch comprising: a patch; and a mesh sheet. The mesh sheet is affixed to and substantially covers the patch; wherein the patch includes one or more perforations. The patch is affixed to an outer edge of a hole in a surface, such that the patch substantially covers the hole. The patch indents and remains substantially indented when a user applies a cement compound onto the patch. A drywall compound is applied to the patch and the mesh sheet. The patch is constructed out of a pliable sheet material. The patch includes an adhesive on at least one side of the patch. The mesh sheet is constructed out of a fiberglass thread material. The surface is a drywall; and the hole comprises a channel cut in the drywall.
- Another embodiment of the present invention is a method of applying a repair patch to a hole in a surface, comprising the steps of: affixing a patch to an outer edge of a hole in a surface, such that the patch substantially covers the hole; wherein the patch includes one or more perforations; applying a cement compound to the patch, such that the cement compound passes through the one or more perforations; and indenting the patch by pushing the patch into the hole. Preferably, the patch includes a mesh sheet affixed substantially over the patch. Preferably, the patch is constructed out of a pliable sheet material. The mesh sheet is typically constructed out of a fiberglass thread material. Preferably, the patch includes an adhesive on at least one side of the patch. The method of applying a repair patch to a hole typically further comprising the step of: applying a drywall compound to the indented and partially rigid patch to form a smooth repair over the hole. The surface is preferably the drywall. Preferably, the patch is an aluminum foil. The hole may be comprised of a channel cut in a drywall.
- Another embodiment of the present invention is a surface repair patch comprising: a patch; wherein the patch adheres to and substantially covers a front side of a hole in a surface. The patch automatically indents over the center of the hole from the pressure created by the action of the patching compound being pressed onto the patch due to the flexible, but semi-rigid nature of the patch. Because the patch is semi-rigid, it will hold the indented shape until the patching compound hardens. Preferably, the patch includes: one or more perforations; wherein the one or more perforations receive the cement compound, such that a portion of the cement compound being pressed onto the patch, flows through the one or more perforations and hardens. Preferably, the surface repair patch, further comprises: a mesh sheet; wherein the mesh sheet is affixed to and substantially covers the patch. The patch is preferably constructed out of a pliable sheet material, and the mesh sheet is preferably constructed out of a fiberglass thread material. The patch typically includes an adhesive on at least one side of the patch. The patch may be a material made of metal foil or another material with similar qualities to a metal foil or a combination of both. The surface is typically a drywall. The hole typically comprises a channel cut in the drywall. A drywall compound should be applied to the indented patch.
- Another embodiment of the present invention is a surface repair patch comprising: a patch; and a mesh sheet. The mesh sheet is affixed to and substantially covers the patch. The patch with the affixed mesh sheet includes one or more perforations. The patch adheres to and substantially covers a front side of a hole in a surface. The one or more perforations receives a cement compound. The patch indents when a user pushes the patching compound onto the patch from the natural pressure one uses during application with a drywall knife. The indentation will hold its shape until the cement compound substantially hardens. A drywall compound is applied to the patch, and the patch is constructed out of a pliable sheet material. The patch includes, but is not limited to, an adhesive, or resin on at least one side of the patch. The mesh sheet is constructed out of a fiberglass thread material. The surface is a drywall; and the hole comprises a channel cut in the drywall.
- Another embodiment of the present invention is a method of applying a repair patch to a hole in a surface, comprising the steps of: affixing a patch to a front side of a hole; wherein the patch includes one or more perforations; applying over the patch a cement compound, such that the cement compound flows through the one or more perforations; and indenting the patch by pushing a central portion of the patch into the hole from the natural pressure created from application with a drywall knife to form a concave portion of the patch in the hole. The repair patch preferably includes a mesh sheet affixed substantially over the patch. Preferably, the patch is constructed out of a pliable sheet material. The mesh sheet should be constructed out of a fiberglass thread material. The patch typically includes an adhesive type of material on at least one side of the patch. The method of applying a repair patch to a hole in a surface, typically further comprising the step of: after hardening of the cement compound, applying a drywall compound to the plaster filled indentation and tensioned patch to form a smooth finished wall surface over the hole and the patch. The surface is typically the drywall, and the patch should be a metal foil. Generally, the hole comprises a channel cut in a drywall.
- It is an object of the present invention to overcome the limitations of the prior art.
- Another object of this invention is to provide a wall patch that is simple, easy to use, professional grade, and inexpensive.
- One of the problems that the present invention solves is how to immediately indent and hold steady a mesh wall patch that is strong enough to support the weight of a drywall compound so that it can be used to smoothly repair a hole in a surface, such as dry wall.
- The drawings are of illustrative embodiments. They do not illustrate all embodiments. Other embodiments may be used in addition or instead. Details which may be apparent or unnecessary may be omitted to save space or for more effective illustration. Some embodiments may be practiced with additional components or steps and/or without all of the components or steps which are illustrated. When the same numeral appears in different drawings, it refers to the same or like components or steps.
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FIG. 1 is an illustration of a perspective view of one embodiment of the invention and shows the patch without a mesh sheet applied to a hole. -
FIG. 2 is an illustration of a cross-section view of one embodiment of the invention without a mesh sheet and shows the patch indented with a cement compound after the first application of drywall compound has been applied only to the center of the patch. -
FIG. 3 is an illustration of a cross-section view of one embodiment of the invention without a mesh sheet and shows the patch indented after application of the drywall compound. -
FIG. 4 is an illustration of a perspective view of one embodiment of the patch with a mesh sheet and shows mesh sheet affixed to the patch. -
FIG. 5 is an illustration of a perspective view of one embodiment of the invention and shows the patch with a mesh sheet applied to a hole. -
FIG. 6 is an illustration of a cross-section view of one embodiment of the invention with a mesh sheet and shows the patch indented after application of the drywall compound. -
FIG. 7 is an illustration of a cross-section view of one embodiment of the invention with a mesh sheet and shows the patch indented and after application of the drywall compound. - In the following detailed description of various embodiments of the invention, numerous specific details are set forth in order to provide a thorough understanding of various aspects of one or more embodiments of the invention. However, one or more embodiments of the invention may be practiced without some or all of these specific details. In other instances, well-known methods, procedures, and/or components have not been described in detail so as not to unnecessarily obscure aspects of embodiments of the invention.
- While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. As will be realized, the invention is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present invention. Accordingly, the screen shot figures, and the detailed descriptions thereof, are to be regarded as illustrative in nature and not restrictive. Also, the reference or non-reference to a particular embodiment of the invention shall not be interpreted to limit the scope of the invention.
- In the following description, certain terminology is used to describe certain features of one or more embodiments of the invention. For instance, the term “drywall compound” refers to any substance that can be used to patch a hole in a wall or other surface, including, but not limited to, any putty, spackle, mud, joint compound, plastic, resin, plaster, veneer plaster, plaster of paris, or other mixture of water, limestone, expanded perlite, ethylene-vinyl acetate polymer, gypsum, and/or attapulgite.
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FIG. 1 is an illustration of a perspective view of one embodiment of the invention and shows the patch without a mesh sheet applied to a hole. As shown inFIG. 1 , the invention is a perforated surface repair patch for ahole 5 inwall 10 and is preferably comprised of apatch 20, adhesive 22,indent 23,perforations 24, andcement compound 26.Patch 20 is adhered, or otherwise affixed or attached, to the front surface, although any surface may be repaired, of thewall 10 along the outer edge or surface of thehole 5. Generally, a pressure sensitive adhesive is the preferred method to adhere, affix, attach, or connect the patch onto the wall or surface to be repaired, but it should be understood that any attachment or connection means may be used. -
FIG. 1 shows howpatch 20 is adhesively affixed overhole 5 such that the entire hole is preferably covered. As shown inFIG. 1 ,patch 20 is preferably constructed out of a thin pliable sheet material. Thepatch 20 may be a pre-cut strip or cut from a large roll of sheet pliable material, and preferably includesperforations 24 configured to receive acement compound 26. The cement compound is preferably any strong liquid or paste that indents the patch upon application for the purpose of allowing thepatch 20 to remain indented until the plaster hardens, and may consist of drywall compound. With the patch in a held indented state, a user may create a smoother and faster repair to the hole by applying a drywall compound 30 (shown inFIG. 3 ) onto theindented patch 20 to complete the repair of the hole. Although only thirtyperforations 24 are shown inFIG. 1 , it should be understood that any number of perforations, or no perforations, may be utilized on thepatch 20. - Preferably, the patch is made of thin, lightweight pliable sheet material such as aluminum foil or other pliable sheet metals, but it should be understood that the patch may be made from any natural or synthetic material, including but not limited to: metal; metal alloy; wood or other fibrous plant product such as hemp, paper, or cardboard; glass; composite materials such as graphite, fiberglass, boron, or aramid fibers; admixtures of plastic resins combined with metal, metal alloy, wood or other fibrous plant product, glass, or composite materials; plastic; animal materials such as wool, bone, or hardened leather; or any combination of these materials, without departing from the scope of the present invention.
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FIG. 2 is an illustration of a cross-section view of one embodiment of the invention without a mesh sheet and shows the patch indented with a cement compound after the first application of drywall compound has been applied only to the center of the patch. As shown inFIG. 2 , the perforated surface repair patch is preferably comprised of: apatch 20, adhesive 22,indent 23,perforations 24, andcement compound 26.FIG. 2 shows how thepatch 20 is affixed to thewall 10 viaadhesive 22.Patch 20 is preferably adhesively affixed to the front side of thewall 10, but any fastening mechanism may be used, including mechanical fastening mechanisms, such as pins, nails, or staples. -
FIG. 2 also shows how thepatch 20 is indented into thehole 5 viacement compound 26. After thecement compound 26 is applied onto thepatch 20, portions of thedrywall compound 26 preferably seep through theperforations 24. Thecement compound 26 sets or hardens after a certain period of time to form apermanent indent 23 onto thepatch 20. -
FIG. 3 is an illustration of a cross-section view of one embodiment of the invention without a mesh sheet and shows the patch indented after application of the drywall compound. As shown inFIG. 3 , the perforated surface repair patch is preferably comprised of: apatch 20, adhesive 22,indent 23,perforations 24,cement compound 26, anddrywall compound 30.FIG. 3 also shows how adrywall compound 30 may be smoothly applied tohole 5, completely repairinghole 5. Thedrywall compound 30 preferably coverspatch 20 when applied, and typically, a layer ofpaint 50, which is not part of the claimed invention and is shown in broken-line form, is applied over the smooth drywall compound to complete the repair. -
FIG. 4 is an illustration of a perspective view of one embodiment of the patch with a mesh sheet and shows mesh sheet affixed to the patch. As shown inFIG. 4 , the patch with a mesh sheet preferably includes: apatch 20;perforations 24; andmesh sheet 35. Thepatch 20, as discussed above, is preferably constructed out of a thin pliable sheet or foil type material, such as aluminum, but may be constructed out of any other natural, synthetic, or man-made or non-manmade material. Theperforations 24 are preferably holes in thepatch 20, which allowcement compound 26 to seep through thepatch 20, allowing a user to form anindent 23 as thecement compound 26 hardens. - The
mesh sheet 35 is preferably constructed of fiberglass material and typically contains a permanent adhesive to adhere, affix, attach, or connect itself to thepatch 20 and/or onto the wall or surface to be repaired. However, themesh sheet 35 may be affixed via any mechanism, and may be made of any material such as solid non-mesh material without deviating from the scope of the invention. If the mesh sheet is a solid material, then it should have perforations, similar toperforations 24, which allow the cement compound to pass through the mesh sheet to thepatch 20 and to theperforations 24. Themesh sheet 35 is typically affixed to thepatch 20 to provide additional support for thedrywall compound 30 to help minimize cracking and is preferably constructed out of fiberglass thread. The small holes that are within themesh sheet 35 preferably allow thecement compound 23 to seep through to thepatch 20 and to theperforations 24. Alternatively, themesh sheet 35, even if mesh, may also have additional perforationssimilar perforations 24. Additionally, in a non-limiting example,mesh sheet 35 may also be drywall tape, tape, or reinforced tape. WhileFIG. 4 shows apatch 20 with amesh sheet 35, it should be understood that the present invention allows the use of apatch 20 without utilizing amesh sheet 35. -
FIG. 5 is an illustration of a perspective view of one embodiment of the invention and shows the patch with a mesh sheet applied to a hole. As shown inFIG. 5 , the surface repair patch is preferably comprised of apatch 20, adhesive 22,indent 23,perforations 24,cement compound 26, andmesh sheet 35.Patch 20 preferably covers overhole 5. Like thepatch 20, themesh sheet 35 typically includesperforations 24 configured to receive acement compound 26. When thecement compound 26 is applied ontopatch 20,patch 20 becomes indented into thehole 5 from natural pressure commonly created from a drywall knife, forming anindent 23. Alternatively, a user may form anindent 23 by indenting the partiallyrigid patch 20. Afterpatch 20 has been indented and sets hard, a drywall compound 30 (shown inFIG. 7 ) is typically administered over themesh sheet 35 andpatch 20 to complete the repair of the hole. As discussed above, the indented patch allows a smoother, faster, and better repair on the hole to be performed. Themesh sheet 35 provides valuable strength to thepatch 20. -
FIG. 6 is an illustration of a cross-section view of one embodiment of the invention with a mesh sheet and shows the patch indented after application of the drywall compound. As shown inFIG. 6 , the repair patch is preferably comprised of: apatch 20, adhesive 22,indent 23,perforations 24;cement compound 26; andmesh sheet 35. Both thepatch 20 andmesh sheet 35 are affixed to thewall 10 via an adhesive 22. Specifically,patch 20 is preferably adhesively affixed to the front side of thewall 10, but any fastening means may be used, andmesh sheet 35 is affixed to patch 20. AlthoughFIG. 6 shows that themesh sheet 35 typically extends beyondpatch 20 to provide additional adhesive binding to thewall 10, themesh sheet 35 may be smaller thanpatch 20 or the same size without deviating from the scope of the invention. Additionally,mesh sheet 35 andpatch 20 may be provided as a single part or may be separate and then later combined.Mesh sheet 35 andpatch 20 may be connected to each other via any adhesive, fastening mechanism, or binding mechanism. -
FIG. 6 also shows thepatch 20 andmesh sheet 35 indented into thehole 5 and held there viacement compound 26. Thecement compound 26 is administered onto and through both thepatch 20 andmesh sheet 35, and, as a result, portions of thedrywall compound 30 preferably seep through theperforations 24 of themesh sheet 35 andpatch 20. Once thecement compound 26 is applied, the center portion of thepatch 20 becomes indented into thehole 5 to form asolid indentation 23. Alternatively, a user may push the center portion of the morerigid patch 20 into thehole 5 to form anindent 23 as thecement compound 26 sets or hardens. -
FIG. 7 is an illustration of a cross-section view of one embodiment of the invention with a mesh sheet and shows the patch indented and after application of the drywall compound. As shown inFIG. 7 , the invention for a perforated surface repair patch is preferably comprised of: apatch 20, adhesive 22,indent 23,perforations 24,cement compound 26,drywall compound 30, andmesh sheet 35.FIG. 7 shows how adrywall compound 30 may be smoothly applied tohole 5, completely repairinghole 5. Thedrywall compound 30 is typically applied and layered over thepatch 20, and the preferably sanded down to be smooth with the rest of the wall. Additionally, a layer ofpaint 50, which is not part of the claimed invention and is shown in broken-line form, may be applied over the smooth drywall compound to complete the repair. - The foregoing description of the preferred embodiment of the invention has been presented for the purposes of illustration and description. While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the above detailed description, which shows and describes illustrative embodiments of the invention. As will be realized, the invention is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present invention. Accordingly, the detailed description is to be regarded as illustrative in nature and not restrictive. Also, although not explicitly recited, one or more embodiments of the invention may be practiced in combination or conjunction with one another. Furthermore, the reference or non-reference to a particular embodiment of the invention shall not be interpreted to limit the scope the invention. It is intended that the scope of the invention not be limited by this detailed description, but by the claims and the equivalents to the claims that are appended hereto.
Claims (20)
1. A surface repair patch comprising:
a patch;
wherein said patch is affixed to an outer edge of a hole in a surface, such that said patch substantially covers said hole; and
wherein said patch indents and remains substantially indented when a user applies a cement compound onto said patch.
2. The surface repair patch in claim 1 , wherein said patch includes one or more perforations;
wherein said one or more perforations receive said cement compound, such that a portion of said cement compound passes through said one or more perforations.
3. The surface repair patch in claim 2 , further comprising:
a mesh sheet;
wherein said mesh sheet is affixed to and substantially covers said patch.
4. The surface repair patch of claim 3 , wherein said patch is constructed out of a pliable sheet material.
5. The surface repair patch of claim 4 , wherein said mesh sheet is constructed out of a fiberglass thread material.
6. The surface repair patch of claim 5 , wherein said patch includes an adhesive on at least one side of said patch.
7. The surface repair patch of claim 6 , wherein said patch is an aluminum foil.
8. The surface repair patch of claim 2 , wherein said surface is a drywall.
9. The surface repair patch of claim 8 , wherein said hole comprises a channel cut in said drywall.
10. The surface repair patch of claim 2 , wherein a drywall compound is applied to said indented patch.
11. A surface repair patch comprising:
a patch; and
a mesh sheet;
wherein said mesh sheet is affixed to and substantially covers said patch;
wherein said patch includes one or more perforations;
wherein said patch is affixed to an outer edge of a hole in a surface, such that said patch substantially covers said hole;
wherein said patch indents and remains substantially indented when a user applies a cement compound onto said patch;
wherein a drywall compound is applied to said patch and said mesh sheet;
wherein said patch is constructed out of a pliable sheet material;
wherein said patch includes an adhesive on at least one side of said patch;
wherein said mesh sheet is constructed out of a fiberglass thread material;
wherein said surface is a drywall; and
wherein said hole comprises a channel cut in said drywall.
12. A method of applying a repair patch to a hole in a surface, comprising the steps of:
affixing a patch to an outer edge of a hole in a surface, such that said patch substantially covers said hole;
wherein said patch includes one or more perforations;
applying a cement compound to said patch, such that said cement compound passes through said one or more perforations; and
indenting said patch by pushing said patch into said hole.
13. The method of applying a repair patch to a hole in a surface of claim 12 , wherein said patch includes a mesh sheet affixed substantially over said patch.
14. The method of applying a repair patch to a hole in a surface of claim 12 , wherein said patch is constructed out of a pliable sheet material.
15. The method of applying a repair patch to a hole in a surface of claim 12 , wherein said mesh sheet is constructed out of a fiberglass thread material.
16. The method of applying a repair patch to a hole in a surface of claim 12 , wherein said patch includes an adhesive on at least one side of said patch.
17. The method of applying a repair patch to a hole in a surface of claim 12 , further comprising the steps of:
applying a drywall compound to said indented and partially rigid patch to form a smooth repair over said hole.
18. The surface repair patch of claim 12 , wherein said surface is said drywall.
19. The surface repair patch of claim 12 , wherein said patch is an aluminum foil.
20. The surface repair patch of claim 18 , wherein said hole comprises a channel cut in a drywall.
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US13/406,976 US8511029B2 (en) | 2010-04-05 | 2012-02-28 | Surface repair patch |
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US12/754,248 US20110239577A1 (en) | 2010-04-05 | 2010-04-05 | Mechanically tensioned wall patch |
US13/406,976 US8511029B2 (en) | 2010-04-05 | 2012-02-28 | Surface repair patch |
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US12/754,248 Continuation-In-Part US20110239577A1 (en) | 2010-04-05 | 2010-04-05 | Mechanically tensioned wall patch |
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US8511029B2 US8511029B2 (en) | 2013-08-20 |
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US13/406,976 Active US8511029B2 (en) | 2010-04-05 | 2012-02-28 | Surface repair patch |
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